Crush-resistant box, box blank, and method of manufacture

ABSTRACT

A box has a plurality of outer panels forming an outer enclosure, and a plurality of inner panels. At least some of the inner panels are disposed in a reinforcing relationship adjacent corresponding ones of the outer panels to resist crushing of the box. The box may include a lid moveable between an open position and a closed position, and which is retained in the closed position by a pattern of perforations. A blank for the box is a sheet-like member having a plurality of panels separated by a plurality of fold lines. The blank is adapted to be folded to define the outer enclosure and inner panels of the box.

BACKGROUND OF THE INVENTION

This invention relates generally to containers, and more particularly to boxes for crush-sensitive products.

Products such as self-adhesive bandages are often shipped and sold in small boxes made from cardboard or other sheet-like materials. These boxes, while lightweight and inexpensive, are often subject to crushing or deformation during the necessary handling when they are packed in large quantities in larger containers, shipped to stores, and stocked on shelves. Crushed or deformed boxes are unsightly and may damage the product contained inside. It is known to make boxes crush-resistant by using thicker materials throughout, or by making the entire box a double-paneled structure. However, this introduces undesired weight and cost to the box.

BRIEF SUMMARY OF THE INVENTION

Therefore, it is an object of the invention to provide a crush-resistant box.

It is another object of the invention to provide a box having some of the panels thereof reinforced.

It is another object of the invention to provide a crush-resistant box which provides clear access to the product contained therein.

It is another object of the invention to provide a box having a reclosable lid.

These and other objects are met by the present invention, which according to one aspect provides a blank for a box including a plurality of panels separated by a plurality of fold lines, the blank including: a plurality of outer panels adapted to be folded to define an outer enclosure, the outer panels including a pattern of fold lines and perforations defining a lid at one end of the outer enclosure, the lid moveable between an open position and a closed position; a plurality of inner panels adapted to be folded to lie inside of the outer enclosure such that at least some of the outer panels are reinforced by an underlying one of the inner panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.

According to another embodiment of the invention, the number of inner panels is one less than the number of outer panels.

According to another embodiment of the invention, a portion of the inner panels underlie the lid when the lid is in a closed position.

According to another embodiment of the invention, the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel is adapted to be folded to reside against the outer front panel.

According to another embodiment of the invention, the inner front panel has a notch disposed at an upper end thereof therein for permitting access to an interior of the inner enclosure when the lid is in the open position.

According to another embodiment of the invention, the panels include, in sequence: a first inner side panel; an inner front panel; a second inner side panel; an outer rear panel; a first outer side panel; an outer front panel; and a second outer side panel.

According to another embodiment of the invention, the blank further includes a plurality of end flaps protruding from upper and lower ends of the outer panels.

According to another embodiment of the invention, at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.

According to another embodiment of the invention, the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.

According to another embodiment of the invention the blank is made from card board.

According to another embodiment of the invention, a box includes: a plurality of interconnected outer panels which define an outer enclosure wherein the outer panels define a lid at one end thereof which is moveable between an open position and a closed position; a plurality of interconnected inner panels disposed inside the outer enclosure, at least some of the inner panels being disposed in a reinforcing relationship adjacent corresponding ones of the outer panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.

According to another embodiment of the invention, one of the inner panels includes a lid tab defined by a tab perforation; and a free end of the lid tab is secured to the lid.

According to another embodiment of the invention, the lid is defined by at least one fold line cooperating with a plurality of perforations such that the lid initially forms an integral part of the outer panels and can be separated along the perforations to fold open about the fold line.

According to another embodiment of the invention, a portion of the inner panels underlie the lid when the lid is in a closed position.

According to another embodiment of the invention, the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel resides adjacent the outer front panel in a reinforcing relationship so as to resist crushing of the box in a side-to-side direction.

According to another embodiment of the invention, the inner front panel has a notch disposed at an upper end thereof for permitting access to an interior of the inner enclosure when the lid is in the open position.

According to another embodiment of the invention, the outer enclosure includes opposed front and back outer panels connected by opposed outer side panels; and the inner panels include opposed inner side panels connected by an inner front panel.

According to another embodiment of the invention, the inner and outer panels are integrally formed from a single sheet-like blank.

According to another embodiment of the invention, the box further includes at least one foot extending downwardly from a bottom panel of the box so as to stabilize the box in a upright standing position.

According to another embodiment of the invention, the box further includes a plurality of top end flaps protruding from the top ends of the outer panels and folded together to form a top end panel; and a plurality of bottom end flaps protruding from the bottom ends of the outer panels and folded together to form a bottom end panel.

According to another embodiment of the invention, at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.

According to another embodiment of the invention, the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.

According to another embodiment of the invention, a method of forming a box includes: providing a blank; folding the blank to define a plurality of inner panels; and folding the blank to define a plurality of outer panels enclosing the inner panels, wherein at least some of the inner panels lie adjacent the outer panels in reinforcing relationship thereto; wherein the outer panels include a pattern of fold lines and perforations defining a lid moveable between an open position and a closed position; and at least one lock tab extends outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.

According to another embodiment of the invention, the method further includes securing at least two of the outer panels together.

According to another embodiment of the invention, the method further includes securing at least one of the inner panels to one of the outer panels.

According to another embodiment of the invention, the outer panels are folded to form opposed front and back outer panels connected by opposed outer side panels; and the inner panels are folded to form opposed inner side panels connected by an inner front panel.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be best understood by reference to the following description taken in conjunction with the accompanying drawing figures in which:

FIG. 1 is a front view of a box blank constructed according to the present invention;

FIG. 2 is a rear view of the blank of FIG. 1;

FIG. 3 is a perspective view of the blank of FIG. 1 before a folding process;

FIG. 4 is a perspective view of the blank of FIG. 1 after a first fold is completed;

FIG. 5 is a perspective view of the blank of FIG. 1 after a second fold is completed;

FIG. 6 is a perspective view of the blank of FIG. 1 after a third fold is completed;

FIG. 7 is a perspective view of the blank of FIG. 1 after interior panels thereof have been completely folded;

FIG. 8 is a perspective view of the blank of FIG. 1 showing exterior panels thereof being folded over interior panels thereof;

FIG. 9 is a perspective view of a partially completed box formed from the blank of FIG. 9 with its top and bottom ends open;

FIG. 10 is a perspective view of the box of FIG. 9 showing a step of closing the bottom end thereof;

FIG. 11 is a perspective view of the box of FIG. 9 with its bottom end closed;

FIG. 12 is a perspective view of the box of FIG. 9 with an open top end and a closed bottom end;

FIG. 13 is a perspective view of the box of FIG. 12 showing a step of closing the bottom end thereof;

FIG. 14 is a perspective view of the box of FIG. 9 with its top and bottom ends closed;

FIG. 15 is a perspective view of the box of FIG. 14 with a lid shown in an open position;

FIG. 16 is a view taken along lines 16-16 of FIG. 14;

FIG. 17 is a front view of the box of FIG. 14;

FIG. 18 is a front view of an alternative box blank constructed according to the present invention; and

FIG. 19 is a perspective view of a completed box formed from the blank of FIG. 18.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings wherein identical reference numerals denote the same elements throughout the various views, FIG. 1 illustrates an exemplary blank 10 for a crush-resistant box. The blank 10 is constructed of a generally planar, sheet-like material which is separated into a plurality of panels by a plurality of fold lines 12. It should be noted that the fold lines 12 may represent physical areas of weakness prone to folding, for example by having been scored or pre-folded, or they may simply be virtual lines along which folds take place during a manufacturing process, described below. Any material which will not tear and which can be folded may be used for the blank. Non-limiting examples of suitable materials include paper, cardboard, plastic, fabrics, and sheet metal. In the illustrated example the blank 10 is constructed from coated cardboard

The blank 10 includes, in left to right order with reference to FIG. 1, inner panels 14 comprising a first inner side panel 14A, an inner front panel 14B, and a second inner side panel 14C. A lid tab 16 is disposed at an upper end of the second inner side panel 14C and connected to the remainder of the second inner side panel 14C by a tab perforation 18. The inner front panel 14B has a notch 20 formed therein. Left and right lock tabs 22A and 22B are defined by cut patterns in the inner panels 14.

Continuing left to right, the blank 10 includes outer panels 24 comprising a outer rear panel 24A with first top and bottom end flaps 26A and 28A, a first outer side panel 24A with second top and bottom end flaps 26A and 28B, an outer front panel 24C with third top and bottom end flaps 26C and 28C, and a second outer side panel 24D with fourth top and bottom end flaps 26D and 28D. A lid fold line 30 and a pattern of lid perforations 32 are disposed across portions of the outer rear panel 24A, first outer side panel 24B, outer front side panel 24C, and second outer side panel 24D to define a lid 34. It should be noted that the particular arrangement of the panels is not critical to the present invention. For example, while the illustrated blank 10 is adapted to form a box having four sides, it could also be adapted for a greater or lesser number of sides.

FIGS. 3-9 illustrate the steps involved in forming box 36 from the blank 10. The inner side panels 14A and 14C are folded so the inner rear panel 14B overlies the outer rear panel 24A and the first inner side panel 14C mates with the first outer side panel 24B. The first inner side panel 14C is then secured to the first outer side panel 24B. Examples of suitable means for securing the two panels include adhesives, fasteners such as staples, interconnecting tabs and slots, and depending on the material used for the blank, sonic welding or heat bonding. As shown in FIG. 7, the blank 10 may be folded upward so that the inner panels 14 define an inner enclosure.

As shown in FIG. 8, the outer panels 24 are folded so that they overlie the inner enclosure forming an outer enclosure, and the second outer side panel 24D mates with the second inner side panel 14C. The second outer side panel 24D is secured to the second inner side panel 14C. Examples of suitable means for securing the two panels include adhesives, fasteners such as staples, interconnecting tabs and slots, and depending on the material used for the blank, sonic welding or heat bonding. The resulting partially completed box 36 with the ends open is shown in FIG. 9.

The exact sequence in which the various panels are folded and secured is not of particular importance. For example, to reduce the cost of shipping, the blank 10 may be folded and secured into a flat shape without the three-dimensional volume shown in FIG. 9. When it is desired to use the blank 10, it is then “broken” or folded open by hand or by machine to form the open-ended box 36 shown in FIG. 9. Furthermore, the folding and securing processes may take place simultaneously or near-simultaneously, for example using a known type of folding and gluing machine.

To complete the box 36, the bottom end flaps 28A-28D are folded inward and secured together, using the securing means described above, to form a bottom end panel 38, as shown in FIGS. 10 and 11. The box 36 is then ready to be loaded with a product (not shown) such as bandages. In some cases the product may be loaded first and then the bottom closed afterwards. The bottom end of the box 36 may optionally include one or more downwardly-extending feet 39 which help the box 36 stand upright on a display shelf.

After the product is loaded into the box 36, the top end is closed off by folding the top end flaps 26A-26D inward and securing them together, using the securing means described above, to form a top end panel 40, as shown in FIGS. 12 and 13.

The completed and closed box 36 is shown in FIG. 14. The box 36 encloses the desired product and protects the product from damage caused by shipping and handling. In particular, the first and second outer side panels 24B and 24D and the outer front panel 24C are all reinforced. In effect, these panels each form a double thickness so as to resist crushing of the box 36 in either fore-and-aft or side-to-side directions, as shown in FIG. 16. Upper portions of the outer front panel 24C, outer rear panel 24A, and outer side panels 24B and 24D form the completed lid 34 which is retained in a closed position by virtue of the intact lid perforations 32.

When is it desired to access the product, the box 36 is broken along the lid perforations 32, and the lid tab 16 is separated at the inner perforation 18, so the lid 34 can be moved to an open position about a “live hinge” formed by the lid fold line 30, as shown in FIG. 15. The cut-down notch 20 in the inner front panel 14B is generally aligned with the outer front panel 24C so as to provide access to view and retrieve the product inside the box. The lid 34 may then be reclosed back down over the inner panels 14. The box 36 retains its reinforced properties to protect the remaining product from crushing. In the closed position, the lock tabs 22A and 22B engage the interior surfaces of the lid 34 to retain it until it is intentionally reopened by a user.

FIG. 18 illustrates an alternative box blank 110 which incorporates a hang tab. The blank 10 is substantially identical in construction to the blank 10 and its construction and use are substantially the same. The blank 110 includes a plurality of inner panels 114, a plurality of outer panels 124, and a plurality of end flaps 126. At least one of the end flaps 126, in this case end flap 126C includes an optional hang tab 125 which is attached to the remainder of the end flap 126C by a pair of tag perforations 127. A center hole 129 suitable for accepting a standard shelf hook (not shown) extends through the hang tab 125. The end flap 126C may include one or more finger notches 131 to ease use of the hang tab 125.

The blank 110 may be assembled into a box 136 which is substantially identical to the box 36. The hang tab 125 initially forms a continuous part of the end flap 126C, and the box 136 may be stocked on a shelf without using the hang tag 125. When it is desired to use the hang tag 125, the tag perforations 127 are broken and the hang tag 125 is folded upwards, exposing the center hole for hanging the box 136 by a standard shelf hook. Although the end flap 126C is separated by this action, the underlying end flap 126C continues to provide a complete closure for the box 136.

The foregoing has described a crush-resistant box, and a blank and a method for making such a box. While specific embodiments of the present invention have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the spirit and scope of the invention. Accordingly, the foregoing description of the preferred embodiment of the invention and the best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. 

1. A blank for a box including a plurality of panels separated by a plurality of fold lines, the blank comprising: a plurality of outer panels adapted to be folded to define an outer enclosure, the outer panels including a pattern of fold lines and perforations defining a lid at one end of the outer enclosure, the lid moveable between an open position and a closed position; a plurality of inner panels adapted to be folded to lie inside of the outer enclosure such that at least some of the outer panels are reinforced by an underlying one of the inner panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.
 2. The blank of claim 1, wherein the number of inner panels is one less than the number of outer panels.
 3. The blank of claim 1 wherein a portion of the inner panels underlie the lid when the lid is in a closed position.
 4. The blank of claim 3 wherein: the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel is adapted to be folded to reside against the outer front panel.
 5. The blank of claim 4 wherein the inner front panel has a notch disposed at an upper end thereof therein for permitting access to an interior of the inner enclosure when the lid is in the open position.
 6. The blank of claim 5 wherein the panels include, in sequence: a first inner side panel; an inner front panel; a second inner side panel; an outer rear panel; a first outer side panel; an outer front panel; and a second outer side panel.
 7. The blank of claim 1 further comprising a plurality of end flaps protruding from upper and lower ends of the outer panels.
 8. The blank of claim 7 wherein at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.
 9. The blank of claim 8 wherein the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.
 10. The blank of claim 1 wherein the blank comprises cardboard.
 11. A box, comprising: a plurality of interconnected outer panels which define an outer enclosure wherein the outer panels define a lid at one end thereof which is moveable between an open position and a closed position; a plurality of interconnected inner panels disposed inside the outer enclosure, at least some of the inner panels being disposed in a reinforcing relationship adjacent corresponding ones of the outer panels; and at least one lock tab extending outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.
 12. The box of claim 11, wherein the number of inner panels is one less than the number of outer panels.
 13. The box of claim 11 wherein: one of the inner panels includes a lid tab defined by a tab perforation; and a free end of the lid tab is secured to the lid.
 14. The box of claim 11 wherein the lid is defined by at least one fold line cooperating with a plurality of perforations such that the lid initially forms an integral part of the outer panels and can be separated along the perforations to fold open about the fold line.
 15. The box of claim 14 wherein a portion of the inner panels underlie the lid when the lid is in a closed position.
 16. The box of claim 11 wherein: the inner panels include at least an inner front panel; and the outer panels include at least an outer front panel, wherein the inner front panel resides adjacent the outer front panel in a reinforcing relationship so as to resist crushing of the box in a side-to-side direction.
 17. The box of claim 15 wherein the inner front panel has a notch disposed at an upper end thereof for permitting access to an interior of the inner enclosure when the lid is in the open position.
 18. The box of claim 11 wherein the outer enclosure includes opposed front and back outer panels connected by opposed outer side panels; and the inner panels include opposed inner side panels connected by an inner front panel.
 19. The box of claim 11 wherein the inner and outer panels are integrally formed from a single sheet-like blank.
 20. The box of claim 11 further comprising at least one foot extending downwardly from a bottom panel of the box so as to stabilize the box in a upright standing position.
 21. The box of claim 11 further comprising: a plurality of top end flaps protruding from the top ends of the outer panels and folded together to form a top end panel; and a plurality of bottom end flaps protruding from the bottom ends of the outer panels and folded together to form a bottom end panel.
 22. The box of claim 21 wherein at least one of the end flaps includes a hang tag having a hole formed therethrough, wherein the hang tag initially forms a continuous portion of the end flap and can be folded away from the end flap to provide access to the hole for hanging the blank thereby.
 23. The box of claim 22 wherein the hang tag is initially connected to the end flap by at least one tag perforation, and wherein at least one finger notch is provided in the end flap for facilitating breaking of the perforation.
 24. A method of forming a box, comprising: providing a blank; folding the blank to define a plurality of inner panels; and folding the blank to define a plurality of outer panels enclosing the inner panels, wherein at least some of the inner panels lie adjacent the outer panels in reinforcing relationship thereto; wherein the outer panels include a pattern of fold lines and perforations defining a lid moveable between an open position and a closed position; and at least one lock tab extends outwardly from the inner panels so as to contact the lid and retain the lid in a closed position.
 25. The method of claim 24 further comprising securing at least two of the outer panels together.
 26. The method of claim 24 further comprising securing at least one of the inner panels to one of the outer panels.
 27. The method of claim 24 wherein the outer panels are folded to form opposed front and back outer panels connected by opposed outer side panels; and the inner panels are folded to form opposed inner side panels connected by an inner front panel. 